UCC28610 DESIGN CALCULATOR TOOL

Disclaimer
This product is designed as an aid for customers of Texas Instruments. No warranties, either expressed or
implied, with respect to this software or its fitness for any particular purpose, are claimed by Texas Instruments
or the author. The software is licensed solely on an "as is" basis. The entire risk as to its quality and
performance is with the customer.

Be sure the Analysis ToolPak box, located in the ADD-Ins section of the Tools menu, is checked.

The UCC28610 is a Green-Mode Flyback Converter that operates in discontinuous current mode or transition
mode over the entire operating range. The controller uses a cascoded configuration which allows fully
integrated current control without an external current sense resistor.

The UCC28610 flyback controller is for use in off-line AC/DC power supply applications of not less than 12W
and not greater than 65W output power. The power limitation of the converter is determined by the peak DRV
current, which must be between 1A and 4A.

The first worksheet, Design Inputs, is where the User enters in the design requirements in the appropriate
cells.

The second work sheet, Calculations, provides key calculated parameters in the design.

The third worksheet, Schematic, provides the schematic and recommended bill of materials for the design.
 UCC28610 DESIGN CALCULATOR TOOL
Disclaimer
This product is designed as an aid for customers of Texas Instruments. No warranties, either expressed or
implied, with respect to this software or its fitness for any particular purpose, are claimed by Texas Instruments
or the author. The software is licensed solely on an "as is" basis. The entire risk as to its quality and
performance is with the customer.

Be sure the Analysis ToolPak box, located in the ADD-Ins section of the Tools menu, is checked.

The UCC28610 is a Green-Mode Flyback Converter that operates in discontinuous current mode or transition
mode over the entire operating range. The controller uses a cascoded configuration which allows fully
integrated current control without an external current sense resistor.

The UCC28610 flyback controller is for use in off-line AC/DC power supply applications of not less than 12W
and not greater than 65W output power. The power limitation of the converter is determined by the peak DRV
current, which must be between 1A and 4A.

The first worksheet, Design Inputs, is where the User enters in the design requirements in the appropriate
cells.
- Fill in the Input Specifications and Output Specifications
- Select Desired Fault Response (either Latchoff or Shutdown/Retry)
- The User Selected Component Parameters will calculate target values for key components.
- The User must input the Actual component values used to complete the calculations

The second work sheet, Calculations, provides key calculated parameters in the design.

The third worksheet, Schematic, provides the schematic and recommended bill of materials for the design.
UCC28610 DESIGN CALCULATOR FOR GREEN-MODE FLYBACK CONVERTER
SLUC113G

CLEAR ALL USER INPUT GREEN CELLS BEFORE STARTING A NEW DESIGN
USER INPUTS
DESIGN REQUIREMENTS USER SELECTED COMPONENT PARAMETERS
Target Actual
INPUT SPECIFICATIONS: Input Bulk Capacitor (CIN) 22.000 22 mF
Minimum Input Voltage 8 VAC FLYBACK INDUCTOR
Maximum Input Voltage 12.6 VAC Primary to Secondary Turns Ratio (NPS) 0.009 0.111 TURNS RATIO MUST BE LOWER
Minimum Line Frequency 47 Hz Primary Inductance (LP) 21.307 5 mH
Brownout Input Voltage 9 VAC Leakage Inductance 0.100 0.15 mH
Primary to Bias Turns Ratio (NPB) 6.655 1.000
OUTPUT SPECIFICATIONS: HVMOSFET
Regulated Output Voltage 1000 Vdc HVMOSFET VDS Rating 30 200 V
Maximum Output Load Current 0.020 A HVMOSFET COSS 5066 150 pF
Output Over-Voltage Threshold 1150 Vdc HVMOSFET CISS 10000 1120 pF
Output Ripple Voltage 0.12 VPEAK-PEAK Minimum Peak Drain Current Rating 8.032 A
RMS Drain Current 1.148 A
OVER-CURRENT AND BROWN-OUT FAULT RESPONSE OUTPUT CAPACITOR
Fault Response SHUTDOWN/RETRY SHUTDOWN/RETRY SELECTED Minimum Output Ripple Current Rating 0.120 0.16 A

Maximum Output Capacitor ESR 269.189 200 mW

Minimum Output Capacitance 1 20 mF

SET BROWNOUT VOLTAGE LOWER

Power level exceeds device capability
 UCC28610 Design Guide Calculations
DESIGN CHARACTERISTICS DRV
Minimum Input Voltage: 11.314 V DRV Schottky Diode (DDRV) Minimum Voltage Rating 30 V
Maximum Input Voltage 17.819 V
Output Power: 20.000 W VGG
Estimated Efficiency: 0.8 VGG Capacitor (CVGG) 0.1 mF
Estimated Input Power: 25.000 W Gate Turn-Off Diode (DGATE) Reverse Voltage Rating 30 V
Estimated Input RMS Current: Err:502 A Gate Turn-Off Diode (DGATE) Average Steady State Current 2.276 mA
Estimated Input Peak Current: Err:502 A Gate Turn-Off Diode (DGATE) Peak Current 4A
Estimated Input Average Current: Err:502 A Start Up Resistor (RSTART) 0.647 MW
Maximum Possible Switching Frequency: 126.984 kHz Start Up Resistor (RSTART) Total Voltage Rating 0V
Minimum Possible Switching Frequency: 26.316 kHz
FB
BRIDGE Filter Capacitor (CFB) 100 pF
Input Bridge Current Rating: Err:502 A Filter Resistor (RFB) 20.500 kW
Minimum Input Bridge Voltage Rating: 0V
MOT
INPUT CAPACITOR, CIN RMOT 36.5 kW
Minimum Input Capacitor Voltage Rating 0V tMOT 1.825 ms
Input Capacitor Value 22.000 mF
Input Ripple Voltage 0.914 V ZCD
Minimum Input Bulk Voltage 10.400 V RZCD1 1100.0 kW
Minimum Input Capacitor Ripple Current Rating Err:502 A RZCD2 44.2 kW
Output Over-Voltage Threshold 1131.093 V
FLYBACK TRANSFORMER, TFLYBACK
Primary to Secondary Turns Ratio 0.111 NPS OUTPUT RECTIFIER (DOUT)
Flyback Voltage 111.144 V Diode Forward Voltage 1.3 V fill in with actual parameter for component used
Initial tON estimate 6.744 ms Reverse Voltage Rating 1508.692 V
First Iteration to Determine Primary Inductance Based on Initial tON Estimate 12.493 mH RMS Forward Current 0.039 A
First Iteration to Determine Peak Primary Current 5.614 A Peak Current 0.446 A
Second Iteration to Determine Primary Inductance Based on Max DRV Current 21.307 mH
Third Iteration to Determine Primary Inductance Based on Min DRV Current 21.307 mH OUTPUT CAPACITOR (COUT)
tON Estimate After Third Primary Inductance Iteration 8.228 ms Minimum Output Capacitance 20.000 mF
Fourth Iteration to Determine Primary Inductance Based on MOTmax 12.689 mH Minimum Voltage Rating 1265.000 V
Final Iteration to Determine Primary Inductance Based on MOTmin 12.689 mH 100kHz Minimum Ripple Current Raitng 0.120 A
Final Resultant Maximum On-Time Based on LPfinal 4.900 ms ESR 200.000 mW
Primary Inductance 5.000 mH Output Voltage Ripple 89.178 mV
Primary to Bias Turns Ratio 1.000 NPB
Leakage Inductance 0.150 mH VOLTAGE FEEDBACK
Maximum On Time 1.931 ms Zener Diode Voltage Rating 10 V fill in with actual parameter for component used
Demagnetizing Time 0.181 ms Opto Forward Voltage 1 V fill in with actual parameter for component used
Time to First Resonant Valley 86.036 ns Series Resistor 1000000 W
Maximum Actual Switching Frequency 126.984 kHz Nominal Output Voltage 1011 V
Primary Side Peak Current 4.016 A
Primary Side RMS Current 1.148 A SNUBBER/CLAMP
Secondary Side Peak Current 0.446 A Clamp Voltage 41.037 V
Secondary Side RMS Current 0.039 A Snubber Capacitor 180 pF
Bias Voltage 109.844 V Parallel Snubber Resistor, RSNUB1 442.000 kW
Power Dissipated in RSNUB1 2.422 W
CURRENT LIMIT Series Snubber Resistor, RSNUB2 31.600 W
RCL 24.9 kW Power Dissipated in RSNUB2 0.003 W
Peak DRV Current 4.016 A
Average Secondary Side Short Circuit Current 0.223 A MODULATION THRESHOLDS
RMS Secondary Side Short Circuit Current 0.257 A Approximate Output Load for Transition from Green Mode to
0.105 W
Minimum Power Limit Threshold (does not include LP tolerance) 3.840 W Amplitude Modulation Mode:
Nominal Power Limit Threshold 4.267 W Approximate Output Load for Transition from Amplitude
0.968 W
Maximum Power Limit Threshold (does not include LP tolerance) 4.693 W Modulation Mode to Frequency Modulation Mode:

HV MOSFET
VDS Rating 200 V
Peak Drain Current 4.016 A
RMS Drain Current 1.148 A
COSS 150 pF
CISS 1120 pF

VDD
Bias Diode (DBIAS) Reverse Voltage Rating 238.663 V
Minimum Bulk VDD Capacitor (CVDD) 47 mF
VDD Zener Diode (VDDZENER) 22 V
 +

PART VALUE
BEAD 4A, 60W to 80W at 100MHz
0V
BRIDGE
Err:502
Cfb 100pF
Cin 22uF

Cout >1uF
Csnub 180pF
Cvdd 47uF
Cvdd_decoupling 0.1uF
Cvgg 0.1uF
Vblocking > 238.66V
Dbias
1A
Vblocking > 40V
Ddrv Steady State Current = 10mA
Peak Surge Current Rating > 10A
Vblocking > 30V
Dgate
Peak Current Rating > 4A
 Vblocking > 1508.69V
Dout RMS Current Rating > 0.04A
Peak Current Rating > 0.45A
Dvdd 22V
Vblocking > 200V
Dsnub
1A
Dzener 10V
VDS Rating = 200V
HVMOSFET Peak Current Rating > 4.02A
RMS Current Rating > 1.15A
5uH
Primary to Secondary Turns Ratio = 0.111
Primary to Bias Turns Ratio = 1.000
Tflyback Peak Primary Side Current = 4.016A
Primary Side RMS Current = 1.148A
Peak Secondary Side Current = 0.446A
Secondary Side RMS Current = 0.039A
OPTO CTR 40%-80%
Rbias 3.3 to 100

Rbode 20.5 to 51.1

Rcl 24.9k
Rfb 20.5k
Rfb_sense 1.00k
Rloop 1000000
Rmot 36.5k
Ropto 100k
Rstart 0.65M
Rturnoff < 5W
Rturnon < 200W
Rsnub1 442k

Rsnub2 31.6
Rzcd1 1100.0k
Rzcd2 44.2k
 +

DESCRIPTION
Ferrite Bead
Input Diode Bridge
Capacitor, Ceramic, 50V, NP0, ±5%
Capacitor, Aluminum Electrolytic, ±20%, 0V
Err:502
Capacitor, Aluminum Electrolytic, ±20%
Ripple Current Rating > 0.12A
Capacitor, Ceramic, 630V, C0G, NP0, ±5%
Capacitor, Aluminum Electrolytic, 35V, ±20%
Capacitor, Ceramic, 50V, X7R, ±10%
Capacitor, Ceramic, 50V, X7R, ±10%
Diode, Ultra Fast

Diode, MUST be Schottky

Diode, Fast Recovery

Diode, Schottky

Diode, Zener, 500mW

Diode, Fast Recovery
Diode, Zener, 500mW

MOSFET, N-Channel

Flyback Transformer, 2% Leakage max.

Optocoupler
Resistor, Chip, 1/10W, ±1%
Smoothing resistor, if needed
Resistor, Chip, 1/10W, ±1%
used as a small signal insertion point
Resistor, Chip, 1/10W, ±1%
NOTE: 24.9k £ Rcl £ 100k
Resistor, Chip, 1/10W, ±1%
Resistor, Chip, 1/10W, ±1%
used to monitor the FB current
Resistor, Chip, 1/10W, ±1%
Resistor, Chip, 1/10W, ±1%
Resistor, Chip, 1/10W, ±1%
Resistor, Chip, 1/8W, ±1%
Total Voltage Rating > 17.82V
Resistor, Chip, 1/10W, ±1%
Resistor, Chip, 1/10W, ±1%
Resistor, Chip, ±1%
Power Dissipation = 2.42W
Resistor, Chip, ±1%
Power Dissipation = 0.00W
Resistor, Chip, 1/10W, ±1%
Resistor, Chip, 1/10W, ±1%
 Std. Resistors
E6 E96
100 150 100 102
150 220 102 105
220 330 105 107
21.5 330 470 107 110
RCL
24.9 470 680 110 113
37.39 680 1000 113 115
RMOT
36.5 E12 115 118
437.50 100 120 118 121
RSNUB1
442 120 150 121 124
31.62 150 180 124 127
RSNUB2
31.6 180 220 127 130
220 270 130 133
270 330 133 137
330 390 137 140
mV factor 1E-03 390 470 140 143
uF factor 1E-06 470 560 143 147
kHz factor 1E+03 560 680 147 150
mΩ factor 1E-03 680 820 150 154
ms factor 1E-03 820 1000 154 158
mA factor 1E-03 E24 158 162
us factor 1E-06 100 110 162 165
uH factor 1E-06 110 120 165 169
ns factor 1E-09 120 130 169 174
mW factor 1E-03 130 150 174 178
pF factor 1E-12 150 160 178 182
MHz factor 1E+06 160 180 182 187
uA factor 1E-06 180 200 187 191
kΩ factor 1E+03 200 220 191 196
nC factor 1E-09 220 240 196 200
nF factor 1E-09 240 270 200 205
uC factor 1E-06 270 300 205 210
MegOhms 1.00E+06 300 330 210 215
330 360 215 221
Kpmin 0.54 360 390 221 226
Kpnom 0.6 390 430 226 232
Kpmax 0.66 430 470 232 237
470 510 237 243
510 560 243 249
RCLmin 24.9 kOhms 560 620 249 255
RCLmax 100 kOhms 620 680 255 261
RCLtest 33.2 kOhms 680 750 261 267
RMOTtest_sd 76 kOhms 750 820 267 274
RMOTtest_latch 383 kOhms 820 910 274 280
tMOTtest_sd 3.8 us 910 1000 280 287
tMOTtest_latch 3.83 us E48 287 294
100 105 294 301
105 110 301 309
110 115 309 316
115 121 316 324
121 127 324 332
127 133 332 340
133 140 340 348
140 147 348 357
147 154 357 365
154 162 365 374
162 169 374 383
169 178 383 392
178 187 392 402
187 196 402 412
196 205 412 422
205 215 422 432
215 226 432 442
226 237 442 453
237 249 453 464
249 261 464 475
261 274 475 487
274 287 487 499
287 301 499 511
301 316 511 523
316 332 523 536
332 348 536 549
348 365 549 562
365 383 562 576
383 402 576 590
402 422 590 604
422 442 604 619
442 464 619 634
464 487 634 649
487 511 649 665
511 536 665 681
536 562 681 698
562 590 698 715
590 619 715 732
619 649 732 750
649 681 750 768
681 715 768 787
715 750 787 806
750 787 806 825
787 825 825 845
825 866 845 866
866 909 866 887
909 953 887 909
953 1000 909 931
931 953
953 976
976 1000
Capacitors
Cap value

C values up to 10nF

1 1.2 197.19826367 pF
1.2 1.5 180 pF
CSNUB
1.5 1.8 1.8
1.8 2.2 2.2
2.2 2.7
2.7 3.3
3.3 3.9
3.9 4.7
4.7 5.6
5.6 6.8
6.8 8.2 Cin_AC t1 0.0026257094563124 s
8.2 10 t3 0.0132640073286528 s
C values greater than 10nF t2 0.0053191489361702 s
1 1.5 tdischarge 0.0079448583924826 s
1.5 2.2 20000000 pF
2.2 3.3 22 uF
Cin_0
3.3 4.7 2.2
4.7 6.8 2.2
6.8 10
First iteration
VBULKmin_1 Err:502 V
t1_1 Err:502 s
t3_1 Err:502 s
t2_1 0.0053191489361702 s
tdischarge_1 Err:502 s
Err:502 pF
Err:502 uF
Cin_1
Err:502
Err:502

Second iteration
VBULKmin_2 Err:502 V
t1_2 Err:502 s
t3_2 Err:502 s
t2_2 0.0053191489361702 s
tdischarge_2 Err:502 s
Err:502 pF
Err:502 uF
Cin_2
Err:502
 Cin_2

Err:502

Third iteration
VBULKmin_3 Err:502 V
t1_3 Err:502 s
t3_3 Err:502 s
t2_3 0.0053191489361702 s
tdischarge_3 Err:502 s
20000000 pF
22 uF
Cin_3
2.2
2.2

VBULKmin 10.2 V
6.085E+09

With ACTUAL VALUE:

Err:502
Err:502
Err:502
0.00531915
Err:502
Err:502
Err:502
Err:502
Err:502

Err:502
Err:502
Err:502
0.00531915
Err:502
Err:502
Err:502
Err:502
 Err:502

Err:502
Err:502
Err:502
0.00531915
Err:502
Err:502 Err:502
Err:502
Err:502
Err:502

Err:502 10.4